System and method for automated casting of infrared glass optical components

Abstract

In accordance with the present invention, a system and method for the automated casting of infrared glass optical components is provided. The system includes a mold for casting infrared glass into lenses, a mold chamber operable to heat the mold to a temperature above the melting temperature of the infrared glass, and a casting chamber operable to fill the mold with molten infrared glass. The method includes heating a mold in a mold chamber to a temperature above the melting temperature of infrared glass, casting molten infrared glass into the mold in a casting chamber; and cooling the mold to a temperature below the glass transition temperature of the infrared glass.

1. A method for the automated casting of infrared glass lenses, comprising:
 heating a mold in a mold chamber to a temperature near a melting temperature of infrared glass, the mold chamber being a first pressurized, heated enclosure having an interior; 
 pouring molten liquid infrared glass into the mold while said mold is in an open position in a casting chamber, the casting chamber being a second pressurized, heated enclosure having an interior; 
 closing said open mold on said molten liquid infrared glass; and 
 cooling the mold to a temperature below the glass transition temperature of the infrared glass; and 
 wherein the mold chamber and casting chamber are coupled together, providing a path of fluid communication between the interior of the mold chamber and the interior of the casting chamber. 
 
     
     
       2. The method of  claim 1 , wherein a pressure isolation valve couples the mold chamber and the casting chamber, and wherein the pressure isolation valve is operable to separate the interior of the mold chamber and the interior of the casting chamber. 
     
     
       3. The method of  claim 2 , further comprising transporting the mold between the interior of the mold chamber and the interior of the casting chamber through the pressure isolation valve. 
     
     
       4. The method of  claim 3 , wherein a transport arm is used to transport the mold between the interior of the mold chamber and the interior of the casting chamber. 
     
     
       5. The method of  claim 1 , further comprising reacting infrared glass constituents to form the molten infrared glass. 
     
     
       6. The method of  claim 1 , further comprising moving the mold around a closed loop within interior of the mold chamber. 
     
     
       7. The method of  claim 6 , wherein the mold is moved around the closed loop within the interior of the mold chamber by a plurality of mold pushers. 
     
     
       8. The method of  claim 1 , wherein the mold chamber is hot-walled. 
     
     
       9. The method of  claim 8 , wherein the mold chamber is externally heated. 
     
     
       10. The method of  claim 1 , wherein the casting chamber is hot-walled. 
     
     
       11. The method of  claim 10 , wherein the casting chamber is externally heated. 
     
     
       12. The method of  claim 1 , further comprising pressing the mold after the mold has been filled with the molten liquid infrared glass. 
     
     
       13. The method of  claim 1 , further comprising annealing the molten infrared glass after it has been poured into the mold. 
     
     
       14. A system for the automated casting of infrared glass lenses, comprising:
 a mold for casting infrared glass into lenses; 
 a mold chamber operable to heat the mold to a temperature near a melting temperature of the infrared glass, the mold chamber being a first pressurized, heated enclosure having an interior; a casting chamber operable to fill the mold with molten infrared glass, the casting chamber being a second pressurized, heated enclosure having an interior; and 
 wherein the mold chamber and casting chamber are coupled together, providing a path of fluid communication between the interior of the mold chamber and the interior of the casting chamber; and 
 wherein said system further comprises: 
 a pressure isolation valve operable to separate the interior of the mold chamber and the interior of the casting chamber; and wherein the pressure isolation valve couples the mold chamber and the casting chamber. 
 
     
     
       15. The system of  claim 14 , further comprising a valve configured to dispense said molten infrared glass into said mold; and wherein said automated system is configured to determine and control the time that said valve is opened to dispense said molten infrared glass into said mold based on a measured weight of molten infrared glass dispensed into said mold. 
     
     
       16. The system of  claim 14 , further comprising a valve configured to dispense said molten infrared glass into said mold; and wherein said automated system is further configured to adjust the time that said valve is opened to dispense said molten infrared glass into said mold based on analysis of previous dispense weights and times. 
     
     
       17. The system of  claim 14 , further comprising: a melt chamber coupled with the casting chamber; and wherein the melt chamber is operable to heat the infrared glass to a molten state and dispense the infrared glass to the casting chamber for casting into the mold. 
     
     
       18. The system of  claim 17 , wherein the melt chamber is further operable to react infrared glass constituents to form the infrared glass. 
     
     
       19. The system of  claim 14 , wherein the mold travels around a closed loop within the interior of the mold chamber. 
     
     
       20. The system of  claim 19 , further comprising: a plurality of mold pushers disposed within the interior of the mold chamber; and wherein the mold pushers are operable to move the mold around the closed loop within the interior of the mold chamber. 
     
     
       21. The system of  claim 14 , further comprising: a mold press disposed within the interior of the mold chamber; and wherein the mold press is operable to press the mold closed once the mold has been filled with the molten infrared glass. 
     
     
       22. The system of  claim 14 , wherein the mold chamber is hot-walled. 
     
     
       23. The system of  claim 22 , wherein the mold chamber is externally heated. 
     
     
       24. The system of  claim 14 , wherein the casting chamber is hot-walled. 
     
     
       25. The system of  claim 24 , wherein the casting chamber is externally heated. 
     
     
       26. The system of  claim 14 , further comprising: a transport arm; and wherein the transport arm is operable to transport the mold between the mold chamber and the casting chamber. 
     
     
       27. The system of  claim 14 , further comprising: a dump tray disposed within the casting chamber; and wherein the dump tray is operable to collect excess infrared glass dispensed in the casting chamber. 
     
     
       28. A method for the automated casting of infrared glass lenses, comprising:
 heating a mold in a mold chamber to a temperature near a melting temperature of infrared glass, the mold chamber being a first pressurized, heated enclosure having an interior; casting molten infrared glass into the mold in a casting chamber, the casting chamber being a second pressurized, heated enclosure having an interior; and 
 cooling the mold to a temperature below the glass transition temperature of the infrared glass; and 
 wherein the mold chamber and casting chamber are coupled together, providing a path of fluid communication between the interior of the mold chamber and the interior of the casting chamber; and 
 wherein a pressure isolation valve couples the mold chamber and the casting chamber, and wherein the pressure isolation valve is operable to separate the interior of the mold chamber and the interior of the casting chamber. 
 
     
     
       29. The method of  claim 28 , further comprising transporting the mold between the interior of the mold chamber and the interior of the casting chamber through the pressure isolation valve. 
     
     
       30. The method of  claim 29 , wherein a transport arm is used to transport the mold between the interior of the mold chamber and the interior of the casting chamber. 
     
     
       31. A method for the automated casting of infrared glass lenses, comprising:
 heating a mold in mold chamber to a temperature near a melting temperature of infrared glass, the mold chamber being a first pressurized, heated enclosure having an interior; 
 casting molten infrared glass into the mold in a casting chamber and controlling the amount of molten infrared glass dispensed into said mold based on a measured weight of molten infrared glass dispensed into said mold, the casting chamber being a second pressurized, heated enclosure having an interior; and 
 cooling the mold to a temperature below the glass transition temperature of the infrared glass; 
 wherein the mold chamber and casting chamber are coupled together, providing a path of fluid communication between the interior of the mold chamber and the interior of the casting chamber. 
 
     
     
       32. The method of  claim 31 , further comprising determining and controlling the amount of molten infrared glass dispensed into said mold based on a measured weight of molten infrared glass dispensed into said mold. 
     
     
       33. The method of  claim 31 , further comprising adjusting the amount of molten infrared glass dispensed into said mold based on analysis of previous dispense weights and times.